Optimal design of solidification processes

An optimal design algorithm is presented for the analysis of general solidification processes, and is demonstrated for the growth of GaAs crystals in a Bridgman furnace. The system is optimal in the sense that the prespecified temperature distribution in the solidifying materials is obtained to maximize product quality. The optimization uses traditional numerical programming techniques which require the evaluation of cost and constraint functions and their sensitivities. The finite element method is incorporated to analyze the crystal solidification problem, evaluate the cost and constraint functions, and compute the sensitivities. These techniques are demonstrated in the crystal growth application by determining an optimal furnace wall temperature distribution to obtain the desired temperature profile in the crystal, and hence to maximize the crystal's quality. Several numerical optimization algorithms are studied to determine the proper convergence criteria, effective 1-D search strategies, appropriate forms of the cost and constraint functions, etc. In particular, we incorporate the conjugate gradient and quasi-Newton methods for unconstrained problems. The efficiency and effectiveness of each algorithm is presented in the example problem

Emergence of foams from the breakdown of the phase field crystal model

The phase field crystal (PFC) model captures the elastic and topological properties of crystals with a single scalar field at small undercooling. At large undercooling, new foam-like behavior emerges. We characterize this foam phase of the PFC equation and propose a modified PFC equation that may be used for the simulation of foam dynamics. This minimal model reproduces von Neumann's rule for two-dimensional dry foams, and Lifshitz-Slyozov coarsening for wet foams. We also measure the coordination number distribution and find that its second moment is larger than previously-reported experimental and theoretical studies of soap froths, a finding that we attribute to the wetness of the foam increasing with time.Comment: 4 pages, 4 figure

Maximin and maximal solutions for linear programming problems with possibilistic uncertainty

We consider linear programming problems with uncertain constraint coefficients described by intervals or, more generally, possi-bility distributions. The uncertainty is given a behavioral interpretation using coherent lower previsions from the theory of imprecise probabilities. We give a meaning to the linear programming problems by reformulating them as decision problems under such imprecise-probabilistic uncer-tainty. We provide expressions for and illustrations of the maximin and maximal solutions of these decision problems and present computational approaches for dealing with them

Equilibrium spherically curved 2D Lennard-Jones systems

To learn about basic aspects of nano-scale spherical molecular shells during their formation, spherically curved two-dimensional N-particle Lennard-Jones systems are simulated, studying curvature evolution paths at zero-temperature. For many N-values (N<800) equilibrium configurations are traced as a function of the curvature radius R. Sharp jumps for tiny changes in R between trajectories with major differences in topological structure correspond to avalanche-like transitions. For a typical case, N=25, equilibrium configurations fall on smooth trajectories in state space which can be traced in the E-R plane. The trajectories show-up with local energy minima, from which growth in N at steady curvature can develop.Comment: 10 pages, 2 figures, to be published in Journal of Chemical Physic

Rapidly solidified titanium alloys by melt overflow

A pilot plant scale furnace was designed and constructed for casting titanium alloy strips. The furnace combines plasma arc skull melting techniques with melt overflow rapid solidification technology. A mathematical model of the melting and casting process was developed. The furnace cast strip of a suitable length and width for use with honeycomb structures. Titanium alloys Ti-6Al-4V and Ti-14Al-21 Nb were successfully cast into strips. The strips were evaluated by optical metallography, microhardness measurements, chemical analysis, and cold rolling

On the role of confinement on solidification in pure materials and binary alloys

We use a phase-field model to study the effect of confinement on dendritic growth, in a pure material solidifying in an undercooled melt, and in the directional solidification of a dilute binary alloy. Specifically, we observe the effect of varying the vertical domain extent ($\delta$) on tip selection, by quantifying the dendrite tip velocity and curvature as a function of $\delta$, and other process parameters. As $\delta$ decreases, we find that the operating state of the dendrite tips becomes significantly affected by the presence of finite boundaries. For particular boundary conditions, we observe a switching of the growth state from 3-D to 2-D at very small $\delta$, in both the pure material and alloy. We demonstrate that results from the alloy model compare favorably with those from an experimental study investigating this effect.Comment: 13 pages, 9 figures, 3 table